Instruction Manual. SonicMax Ultrasonic Cleaning Systems. Graymills

Transcription

1 GM 9-11 Instruction Manual SonicMax Ultrasonic Cleaning Systems Graymills The information contained in this manual is intended to be accurate. However, the manufacturer retains the right to make changes in design which may not be included herein.

2 Safety Disclaimer Care has been taken to ensure the accuracy of the information. No liability can be accepted for any errors or omissions found in this manual. The publisher of this manual reserves the right to revise this publication and make changes from time to time in its content without notice. Explanation of Safety Symbols NOTE DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. Note messages provide additional information or helpful tips. Operator Training This equipment should only be operated by personnel trained for its use. This training should include electrical safety, machine operation, familiarity with the cleaning solutions, and emergency procedures. Important Safety Notifications DO NOT USE cleaning liquids classified as FLAMMABLE or COMBUSTIBLE in this cleaning unit. It is not equipped with the safeguards necessary for cleaning with combustible chemicals. Be sure the work area is well-ventilated. DO NOT INHALE VAPORS. Do not allow vapors to exceed maximum allowable MSDS concentrations. High voltages exist when the unit is plugged in. Always disconnect power before servicing machine. When operating the system, observe all operating precautions in this manual and applicable electrical codes. For every cleaning fluid used, a Material Safety Data Sheet (MSDS) should be maintained nearby. Before using, read all manufacturer and MSDS instructions and refer to them whenever there is a use question. Before working, tightly secure loose hair, jewelry, clothing, and personal effects that could be drawn into moving machinery. Failure to do this may result in serious personal injury. Avoid pinch injuries to fingers when working near moving parts. Never place your hands, arms, or any body part in the cleaning or rinse liquids when ultrasonic cleaning is in operation. Always use racks, baskets, or tongs for inserting and removing objects from the cleaning tank. NOTE Consult Graymills before selecting or changing detergents to confirm compatibility. Never use a flammable or combustible liquid in an ultrasonic unit. 1

3 Hazards Overview Several hazards may be present when operating or servicing the system and extreme caution must be exercised at all times. The hazards that may be encountered include: Burn and Scald hazards Electrical hazards Mechanical and Lifting hazards NOTE Use of controls, replacement parts, adjustments or procedures other than those specified within this manual may result in increased exposure to any of these hazards. Burn and Scald Hazards Hot Surface Hazard This system can operate at high liquid temperatures. Washed parts will be HOT. Use appropriate protective equipment. PPE When performing maintenance operations, use appropriate protective equipment. For safety reasons it is best to wait until all components and fluids have cooled sufficiently. Hot Liquid Splash Hazard Unit can operate at high temperatures. There is potential of splashing when immersing and removing basket and parts. PPE Appropriate safety equipment is recommended. Electrical Hazards Electrical Safety Precautions High Voltage Hazards: Generator is producing high output voltage through the HV-BNC connectors at the back of the generator. The maximum values at output are: Vpeak up to 1250V and Vrms up to 530V. Disconnect and lockout/tagout system prior to servicing. Power to this system is provided by 115VAC / Single phase/ 60 Hz on model CTU2012-A 230VAC / Single phase/ 60 Hz on all models except those noted. 230VAC/ Three phase/ 60 Hz on model CTU4723-J Disconnect power and initiate lockout/tagout prior to servicing. Read the operating instructions of the system before commencing any service. Only trained personnel should remove electrical access covers. Follow requirements of local electrical safety codes.never wear rings, bracelets or other jewelry when working around electrical circuits. Never work on electrical equipment alone. Always have a colleague nearby. Always verify that electrical connections and components are correct before installing. Never operate the system if any power cable is frayed or damaged. Never operate the system with safety and/or electrical access covers removed. 2

4 Ultrasonic Generators Generators are installed to the cleaning system and should not be removed from its casing except for service purposes. Only trained personnel should remove the generator from the casing. Mechanical and Lifting Hazards Secure loose hair that could become entangled. Do not wear loose fitting clothing, neckties or jewelry that could become entangled in moving machinery. Identify the working envelope of the system with floor marking, signs and barriers. Provide sufficient room to permit safe teaching and maintenance procedures. Always adhere to local or company safety regulations. Use appropriate safe lifting procedures when handling heavy parts/loads. On models with lids having two handles, lift tank lids with both hands. System Overview The cleaning system is equipped with single and/or dual point connections for electricity. Configurations for connections to the system are cabled plugs located at the rear-side of the console for interconnection to facility. Required facilities connections will include power, water and drain. The tank is fabricated from 316L stainless steel and direct bonded ultrasonic transducers to tank bottoms. tanks are fitted with strip heaters located on side and/or rear walls. The system features generators that are uniquely designed to provide the operator with consistent performance and process control. The result is that the same parameters used to perform a cleaning process can be repeated. Each generator features constant high output power control to ensure consistent output despite fluctuations in line voltage, solution depth, solution temperature or tank loading. Sweep frequency is included to help eliminate inconsistent cleaning due to standing waves or areas of overly intense ultrasonic activity (hot spots). Each generator features independent amplitude power intensity control to allow the operator to vary the intensity of the ultrasonic power from approximately 15% to 100%. Plumbing components and generators are easily accessible from all sides of frame. Electrical components are located in a removable front mounted control panel for ease of service. The console is provided with an operator control panel at the front of each unit with thermostat and ultrasonic timer controls as well as a side-mounted recirculation pump ON/OFF switch box. Systems are plumbed with a pull-through filter unit fitted with a 50micron element. Filter elements are washable and re-useable multiple times before needing replacement. 3

5 SonicMax Series Systems Specifications Model/Size Depth Ultrasonic Power (Avg) Fluid Capacity Heater Wattage Basket Dimensions System Dimensions Operating Voltage 750W 1500W 3000W 2000W 3500W 4000W 5000W 7 gal 18 gal 42 gal 33 gal 54 gal 65 gal 87 gal * 17 x10 x5 25 x11 x7 25 x23 x12 32 x14 x11 32 x21 x13 44 x16 x15 44 x21 x16 38 x28 x37 46 x33 x40 46 x37 x40 52 x37 x42 52 x37 x42 64 x37 x45 64 x37 x45 115/60/1 230/60/1 230/60/1 230/60/1 230/60/1 230/60/1 230/60/3 *Reduced during Sonic timed operation Installation Site Preparation and Uncrating Locate the system in an appropriate place that allows adequate flow of air and ventilation. Verify that the type of electrical power required by your model is available nearby (See Specifications above). It is recommended that water supply and drain be present. It is recommended that the unit is placed on a flat, level surface with at least 42 inches of maintenance work space reserved in each direction from the system for service accessibility as well as personnel safety. Be sure to follow local grounding procedures as required for this type of system. Do not operate this system without proper ground connections. The detergent waste should be handled and disposed of according to local codes and manufacturer/msds instructions. Equipment should be carefully uncrated and inspected for damage. Follow your facility s standard procedures for making notification if any shipping damage is found. Operation Operating the system with any portion of the safety systems or procedures bypassed can result in severe system damage and human injury. Never operate the unit with a low liquid level. Always ensure that liquid level is at FILL LINE prior to use. 4

6 Pump Outlet (Valve 4) Overflow Return Tank Drain front of unit, not shown (Valve 1) Tank Return (Valve 3) Pump/Filter Drain (Valve 2) Piping Diagram Initial Set-Up and Operating Procedure 1) Verify that both the front control panel mounted thermostat knob and side mounted pump switch are in the off position. 2) Verify all plumbing valves are set in the following positions: Valves 1 and 2 are fully closed and valve numbers 3 and 4 are adjusted halfway open. Never start the pump with valves 3 and 4 closed. See Piping Diagram above. 3) Remove the lid(s) and basket(s) from unit. 4) Inspect fluid level in tank. If tank is empty, perform Steps 4a through 4c to fill tank with cleaning solution. If fluid level in tank is below FILL LINE and/or overflow weir is less than 1/3 full, perform Step 4d to top off fluid level. If fluid is at FILL LINE and overflow weir is 1/3 to 1/2 full, proceed to Step 5. a. Begin to fill main tank with water (preferably heated to standard hot water heater F) until liquid is just below FILL LINE mark etched on inside rear wall of tank. b. Carefully and with protection from splashing and in accordance to MSDS begin to add concentrated detergent to main tank as directed in detergent instructions. Liquid may begin to spill over into the overflow weir. c. Check liquid level in overflow weir. Liquid level should be roughly 1/3 to 1/2 full without basket and parts in main tank. For optimal performance, the level in the weir after basket and parts have been submerged should be at least 2 inches lower than the fluid level in main tank, which should be at the FILL LINE. If necessary add water to overflow weir. If using pre-mixed cleaning solution, perform Steps 4a through 4c without concern for mixing fluids: fill main tank to FILL LINE and overflow weir to approximately 1/3 to 1/2 full. Take care to minimize splashing and follow all instructions on solution label and MSDS. d. If fluid levels are low, add sufficient pre-mixed cleaning solution of the same kind already present in unit to return fluid level to FILL LINE and bring overflow weir to approximately 1/3 to 1/2 full. Take care to minimize splashing and follow all instructions on detergent/solution label and MSDS. 5) Turn thermostat control knob to desired process temperature. The green pilot light next to the thermostat will illuminate, indicating that the heater is running. 6) Turn pump switch to On position. 5

7 7) Replace lid(s) and turn sonic timer switch located on front panel to 15 minutes. This will allow the ultrasonics to degas any new liquid as well as aid in heating prior to your system s first cleaning (see Degassing for more information). The heat-up time will vary depending on the initial temperature of your solution, but is generally between minutes. 8) Once the green pilot light has turned off, the system has reached the desired temperature set point and is ready to process parts. 9) While wearing appropriate protection, remove tank lid(s). Place parts in basket(s) provided and lower basket(s) into tank until handles rest on counter lip area (never clean parts in bottom of tank without basket). Replace lid(s) over basket(s) and turn sonic timer to desired process time. Process times will vary depending on the part(s) and their condition. 10) When timer has stopped, remove lid(s) and remove basket(s) slowly. Rest basket(s) above tank to allow cleaning solution to drip back into tank. Remove basket(s) and part(s) from rest and cover tank. Rinse part(s) as recommended. Cleaning solution, counter, and lid surface area and become HOT! Eye and Skin protection should be used. 11) If no additional parts are to be cleaned, turn off unit as described in Shut Down System. Degassing Any liquid will retain dissolved gases. For an ultrasonic cleaner to work properly, the dissolved gases must be driven out of solution. The cleaning power of an ultrasonic comes from the collapse of the vacuum cavity or bubble. If there is any dissolved gas in the cleaning fluid it will migrate to the area of lowest pressure (the vacuum cavity), preventing the collapse of the cavity and reducing the cleaning power. Perform the following any time new cleaning solutions is added to the unit prior to part cleaning: Step 1 Adjust the Ultrasonic Timer to 15 min. Description 2 The recirculation pump should be OFF during degassing. 3 The Ultrasonics will turn OFF automatically when the timer has elapsed. Shut Down System Tank walls remain HOT for a period of time after the unit is turned off. Exercise appropriate caution when performing cleaning and maintenance operation. Wear appropriate protective clothing, or wait until the tank walls have cooled. Step Description 1 When the machine is not in use, power down the system properly. 2 Check that Heater Thermostat, Ultrasonic Timer and Pump Switch are in the OFF positions. 3 Clean the tank and drain the system completely as needed to maintain a clean tank bottom. See Preventative Maintenance for more details. 6

8 Preventative Maintenance System Views and Components Ultrasonic Timer Heater ON pilot light Thermostat Heater Circuit Fuse Pump Switch Housing 7

9 Pump Housing Drain Valve for Pump and Filter Filter Housing Assembly 8

10 Preventative Maintenance Schedule Item Tanks PM Activity/Schedule Drain, clean, and refill water for all wet tanks (wash, rinse, reservoir, etc.). At Least Weekly Plumbing Check plumbing for leaking. Daily Electrical Check Cabling and plugs for fraying or loose connections only with power disconnected. Quarterly Plumbing Changing filter. As Needed Plumbing Close inspection to verify there is no leakage. Monthly Components and fluids will remain hot for a period of time after unit is turned off. ow time to cool down before performing service. NOTE NOTE Do not use abrasive cleanser, which may damage the tank surface. Always exercise care not to scratch, dent, or gouge tanks surfaces. Filter change-out requirements are strongly dependent upon process specifications and may vary significantly from one process to another. Maintaining a record detailing the cleaning processes and system maintenance performed can aid in predicting the frequency of filter change-out. Drain, Clean, and Refill Step Description 1 Ensure that pump, ultrasonics, and heater are off. ow hot solution and surfaces to cool. Unplug unit from outlet(s). 2 Place a container under drain valve near pump and under tank drain at front of unit. Ensure that valves 3 and 4 are not fully closed. Drain main tank and overflow weir (open valve 1). Open Pump drain (valve 2) and drain. Take care to minimize splashing and follow cleaner label and MSDS instructions. 3 Clean tank bottoms whenever tanks are drained. Remove any foreign objects. This is necessary to minimize the possibility of small objects becoming lodged in a drain line, resulting in a service issue. 4 Inspect tank walls for accumulation of deposits or other contaminants. If tank walls require cleaning, cleanroom wipes or the equivalent are recommended. 5 Close valves 1 and 2 and refill unit with new solution according to instructions in Operating Procedure. Servicing Filter Cartridge Step Description 1 Ensure that pump, ultrasonics, and heater are off. Unplug unit from outlet(s) or disconnect main power, as applicable. ow hot solution and surfaces to cool. 2 Place a container under the filter drain valve near pump and under tank drain at front of unit. Ensure that valves 3 and 4 are not fully closed. Drain main tank and overflow weir (open valve 1). Open Pump drain (valve 2) and drain. Take care to minimize splashing and follow cleaning solution label and MSDS instructions. 3 Place a container under the filter housing. While wearing appropriate safety equipment and taking care to avoid splashing, unscrew filter housing with supplied wrench. 4 Remove filter cartridge. Filter is washable and can be used multiple times. If the filter is unfit to be returned to service, dispose of properly. 9

11 Step Description 5 Remove debris and sludge from inside the inlet portion of housing to avoid interference with cover seal or flow of fluid being filtered. 6 Install clean filter. Be sure filter is properly seated inside the housing. 7 Inspect cover gasket for cuts or other signs of failure, replacing if necessary, and make sure it is properly seated. 8 Re-install housing on filter head. Avoid over-tightening or damage to head and housing may result. Close drain valves and refill system as noted in start-up procedures. Parts List Models Description Filter Element 50 micron* Pump Switch Assembly Pump Switch Overload Thermostat 0-250F 0-30 Minute Timer Pilot Light 2012,2814,3516 Front Panel Fuse ABC ,3523,4718,4723 Front Panel Fuse ABC5 Pump Hose (by the foot) Hose clamp 2825,3523,4723 Sonic Contactor C Sonic Contactor C Sonic Fuse KTK Heater Contactor C ,3523,4718,4723 Heater Contactor C ,3523,4718 Heater Fuse KTK Heater Fuse KTK Heater Fuse KTK Relay 2-pole 4723 Relay Base * Other micron sizes available: 20,

12 Warranty Information Graymills Corporation warrants that the equipment manufactured and delivered hereunder when properly installed and maintained, shall be free from defects in workmanship. This warranty does not apply to damages or defects caused by operator carelessness, misuse, abuse, improper application, or abnormal use; the use of add-on parts or equipment which damages or impairs the proper function of the unit and modifications made by Buyer. Graymills obligation under this Warranty shall be limited to: 1. Replacing or repairing tank and structural parts within one year from the date of installation or 13 months from the date of shipment whichever occurs first. The decision to replace rather than repair shall be made by Graymills Corporation; 2. Replacing or repairing components supplied but not manufactured by Graymills, such as pneumatic cylinders, controls, pneumatic systems, motors, heater controls and heaters to the extent such components are warranted by the original manufacturer s warranty, provided that Buyer gives Graymills prompt notice of any defect or failure and satisfactory proof thereof. Before Graymills can repair or replace a defective part under warranty, call Graymills for a Return Merchandise Authorization number (RMA number must appear on outside of package or it will be refused and returned). Upon prepaid return to Graymills factory, Graymills examination must disclose such part to be defective. This warranty does not apply to expendable parts such as rollers, bearings, cylinder packings and any other parts which need replacement periodically due to normal wear nor to rusting of a mild steel heated unit used with aqueous (water) based cleaning solutions. A new warranty period shall not be established for repaired or replaced materials, or products. Such items shall remain under warranty for only the remainder of the warranty period of the original materials or products. Graymills warrants that the equipment will function mechanically as quoted in the published specification. Graymills does not warrant process performance nor does Graymills assume liability for equipment selection, adaption or installation. The foregoing warranties are in lieu of all other warranties whether oral, written, expressed, implied or statutory. Implied warranties of fitness for a particular purpose and merchantability shall not apply. Graymills warranty obligations and Buyer s remedies thereunder (except as to title) are solely and exclusively as stated herein. In no case will Graymills be liable for consequential damages, loss of production or any other loss incurred because of interruption of service 11